Being on the hunt for the 2m coil cable for a while now. Currently building a system similar to the original FD2.
There are 3 core 2.5mm cables available on the market e.g:
ÖLFLEX® SPIRAL 400 P (same brand FD uses for their own cables)
I’ve collected the reading from the remote with 11S3P battery the system uses 25A on average and 40-45A during takes offs, which puts 2.5mm2 sections to the limit (on the paper) making it not an easy choice to make.
I’ve checked all the topics on the forum so far only few people shared their experience and its mostly using similar spec cable of 3G 2.5mm2
Did someone found a manufacturer that produces thicker cores closer to 4mm2? Or had experience coiling up existing straight cables?
Duotone should release about now there setup which also uses the nice half straight/half coil cable setup partially reinforcing that this might be indeed a good direction to explore for now
Heaps of options on Aliexpress. PUR is the same sheath that Foil Drive specify on their cables - super tough. Bit confusing on the site but you can get slightly heavier than 2.5mm2 per conductor. Think that is 13awg
I just found this on AliExpress: AU$15.59 | Spring Spiral Power Cable PUR Polyurethane Jacket Retractable Cord 2/3/4/5/6/7/8Core FlexibleTensile Extened Signal Control Wire https://a.aliexpress.com/_mqE83QV
Consider also a thinner cable can be used, it will be water cooled when you are stopped, and not carrying current during off power riding. A quite small cable is likely ok especially if a boost time limit is imposed, such as a few minutes.
PFA jacket is the top tier you can get, likely only find PUR in normal 3 conductor stock. Likely a cable manufacturer in china would be the best chance to get a custom cable with high strand counts, round outer section and durable insulation.
Its easy to coil your own cable using rod and heat gun. most import tip — a specific technique is used to reverse the coil to give it more snap spring action
I got some coil cable from Aliexpress a few months ago to try this (3 x 2.5mm2) and it ended up being a waste of time. The cable weighed a lot and was not really workable (just think of a 500g mass flapping around between you and the board…). I’m interested to hear what people that have used coil cables say about this…
I’ve ended up running a straight cable up into a hydration pack with my box, and I have a metre of spare cable in the pack that can be pulled out if I have a big wipeout (my leash extends about .8m max. It means for the time I’m foiling I only have a lightweight leash (I use an old wing leash from the board to hydration pack). My motor cable overall is 4m long, with a 6384 motor. I’ve been running this setup now for about 10 sessions, some have been in decent waves with decent wipeouts and it is working great.
Side note if anyone in NZ wants to try some coil cable I’ve got some that I wont ever use … send me a message if you want it.
Thank you for sharing I’ve seen these videos. Have you tried yourself? I currently don’t feel confident doing so and be sure that I didn’t damage internal insulation by overheating certain sections
There are also other videos on youtube how its done professionally on the factories where people have access to machines that can produce consistent temperatures that are under the limit where the insulation will be damaged
I’ve been running straight cable with my backpack very successfully. It’s the Ollflex PUR sheath 3G2.5, same as foil drive use.
I use a regular straight 6mm leash and run both inside 50mm tubular polyester webbing. The leash is about 100mm shorter than the cable. I also have a pull apart connector mid cable for worst case scenarios!
I recently had to shorten the leash because it had stretched a bit but apart from that it’s been faultless.
I’m running 12S2P XCross 120 and Flipsky 6374. Pretty serious strain relief on both ends of the cable to ensure the connector gives first. Had plenty of cases of the connector being pulled apart and I can re connect on the water with no issue at all. Generous dielectric great on the 5.5mm bullets and silicone grease on the cover. I’m loving it, using 46L board and it’s great to get the weight off it. Very high motor mount so just chugging along with board just skimming to get back out etc.
Thanks for sharing so if I understood you correctly the cable is super well secured on the both ends (e.g board/foil track and on the belt/back pack area).
And in the middle of the cable it has bullet connectors with dielectric grease applied to them that would pull apart first in case the leash would snap?
Correct, I designed a pull apart plug and printed it in Tpu. Then flooded the plug with epoxy to secure everything. Inspired by Hangloose plug and socket.
Started with petg by the alignment was super critical, the give in the tpu made all the difference. I printed a little clamp for the cable where it leaves the board.
Also made the backpack part from a flat sheet of 6mm Starboard, routed slats etc and bent it to fit my back then sewed on straps, way less flopping around than a backpack and doesn’t hold water or restrict air flow over the esc
That’s great setup, thank you for sharing. I have wing harness from from EVA foam and hardshell (highly resembles kitesurf harness but not as bulky form Mystic brand) that I am trying to repurpose for the foil assist now
I friend of mine suggested using eletrical relay inside the electric box that will disconnect the system if the cable would start to get pulled out of the box, it seems nice but still has more destructive consequences comparing to the self “release” concept
I am bit shocked with the statement that you can reconnect it even in the water?
Did you really attempt that?
… send me a message if you want it.
